Tortuous path control valve trim

Abstract

A valve component and method for controlling fluid flow comprises a body having a first surface and a second surface. At least one tortuous flow channel extends between the first surface and the second surface. The flow channel is at least partially defined by a floor portion and a ceiling portion. The body is formed as one-piece by additive manufacturing to concurrently define the flow channel as a void space. At least one of the floor portion and ceiling portion is disposed at an acute angle relative to a plane containing a layer of material forming the body.

What is claimed is: 
     
       1. A method of manufacturing a unitary trim cage, the method comprising the steps of:
 forming at least one layer of material to define a body base with an inner opening surface and an outer surface; 
 adding successive layers of material to the body base along a lay down direction and in such a manner to maintain the inner opening surface and define at least one tortuous flow channel extending between the inner opening surface and the outer surface, the tortuous flow channel including a plurality of sections, each section of the flow channel offset relative to adjacent sections along the lay down direction and the surfaces defining the flow channel are accomplished without internal support, and at least a portion of each section extends at an acute angle relative to the direction of additive lay down; and 
 adding at least one layer of material to define a body cap in such a manner to maintain the inner opening surface and the outer surface, 
 wherein the flow path has a chevron cross-sectional shape and a first part that extends radially from the inner opening, a second part that extends transverse to the first part and terminates at a location lower than the first part, and a third part that extends radially from the location of the second part to the outer opening. 
 
     
     
       2. The method of  claim 1 , wherein the trim cage has an axis and the layers of material added being substantially in a plane extending orthogonally relative to the axis, the acute angle being at least 45° and each section of the flow channel is offset relative to an adjacent section in the lay down direction. 
     
     
       3. The method of  claim 1 , wherein the trim cage is made by a direct metal laser melting additive layer manufacturing process. 
     
     
       4. The method of  claim 1 , wherein the material is selected from a group of metal powders comprising: stainless steel based powders; nickel & cobalt based powders; iron based powders; titanium based powders; aluminum based powders; and combinations thereof. 
     
     
       5. A method, comprising:
 forming a cylindrical tube of unitary structure with a center axis and a wall circumscribing the center axis, the wall forming an inner surface and an outer surface; and 
 populating the cylindrical tube with apertures forming a flow path in the wall, the apertures extending radially outwardly from an inner opening to an outer opening found on the inner surface and the outer surface, respectively, 
 wherein the flow path has a chevron cross-sectional shape and a first part that extends radially from the inner opening, a second part that extends transverse to the first part and terminates at a location lower than the first part, and a third part that extends radially from the location of the second part to the outer opening. 
 
     
     
       6. The method of  claim 5 , wherein the cylindrical tube comprises sintered metal. 
     
     
       7. The method of  claim 5 , further comprising:
 using a laser to melt powdered metal to form the cylindrical tube. 
 
     
     
       8. The method of  claim 5 , further comprising:
 building the unitary structure from successive layers of sintered metal. 
 
     
     
       9. The method of  claim 5 , further comprising:
 overlapping successive layers of material to form the unitary structure of the cylindrical tube. 
 
     
     
       10. The method of  claim 5 , wherein the outer opening comprises a pair of openings spaced annularly from one another on the outer surface. 
     
     
       11. The method of  claim 5 , wherein the flow path comprises a first section and a second section that is radially and annularly offset from the first section. 
     
     
       12. The method of  claim 5 , wherein the chevron cross-sectional shape comprises rounded corners disposed on sides that are annularly offset from one another. 
     
     
       13. The method of  claim 5 , wherein the chevron cross-sectional shape comprises sides that are annularly offset from one another that meet at an apex that aligns with a center axis of the cylindrical tube. 
     
     
       14. The method of  claim 5 , wherein the apertures are disposed variously around the center axis of the cylindrical tube. 
     
     
       15. A method, comprising:
 using additive manufacturing to form a valve component, the valve component having a thin, annular wall circumscribing a center axis, the thin, annular wall comprising an interior labyrinth structure with apertures extending radially from the center axis, the apertures forming a flow path having a cross-section comprising planar surfaces numbering at least 4 but not more than 6, at least two of the planar surfaces mating to form an acute angle, 
 wherein the flow path has a chevron cross-sectional shape and a first part that extends radially from the inner opening, a second part that extends transverse to the first part and terminates at a location lower than the first part, and a third part that extends radially from the location of the second part to the outer opening. 
 
     
     
       16. The method of  claim 15 , wherein the planar surfaces form an upper boundary and a lower boundary of the cross-section, and wherein the acute angle forms at both the upper boundary and the lower boundary. 
     
     
       17. The method of  claim 15 , wherein the planar surfaces include planar surfaces that mate at a rounded corner. 
     
     
       18. The method of  claim 15 , wherein the cross-section has a height and a width, and wherein the width is larger than the height. 
     
     
       19. The method of  claim 15 , wherein the apertures are disposed variously around the center axis of the annular wall.